CN117642345A - Mechanical treatment device - Google Patents

Abstract

An apparatus for handling containers or boxes, the apparatus being configured to: receiving containers from a branch and first location of a semi-automatic or automatic storage and retrieval system; moving the container to a second position corresponding to a predetermined location relative to the loading frame; and moving the container into a first destination location of the loading frame. Alternatively, the container may then be moved to a second destination within the loading frame.

Description

Mechanical treatment device

Technical Field

The present invention relates generally to the field of mechanical handling devices, and more particularly to a device and method for automatically handling boxes or delivery containers, such as would be used in a warehouse environment or the like, so that the boxes or delivery containers can be loaded into a delivery framework and subsequently reloaded into a delivery vehicle.

Background

On-line retail establishments such as on-line groceries and supermarkets that sell multiple product lines require systems capable of storing tens or even hundreds of thousands of different product lines. In such a case, it may be impractical to use a single product stack, as this requires a very large floor area to accommodate all of the required stacks. Furthermore, it may be necessary to store only small amounts of certain goods (e.g., perishable or infrequently ordered items), which makes stacking of individual products an inefficient solution.

International patent application WO 98/049075A (Autostore), the contents of which are incorporated herein by reference, describes a system in which stacks of multi-product containers are arranged within a framework structure.

PCT patent No. WO2015/185628A (Ocado) describes a known storage and fulfillment system in which a stack of bins or containers are arranged within a frame structure. The bins or containers are accessed by load handling equipment running on rails located on top of the framing structure. The loading handling apparatus lifts the bins or containers out of the stack and the plurality of loading handling apparatuses cooperate to access the bins or containers located at the lowest position of the stack. Fig. 1 to 4 of the accompanying drawings schematically show a system of this type.

As shown in fig. 1 and 2, stackable containers (referred to as bins 10) are stacked on top of each other to form a stack 12. The stacks 12 are arranged in a grid framework structure 14 in a warehouse or manufacturing environment. Fig. 1 is a schematic perspective view of a frame structure 14, while fig. 2 is a top view showing a stack 12 of boxes 10 arranged in the frame structure 14. Each bin 10 typically houses a plurality of product items (not shown), and the product items within the bins 10 may be of the same product type, or of different product types, depending on the application.

The frame structure 14 includes a plurality of upright members 16 that support horizontal members 18, 20. The first set of parallel horizontal members 18 are arranged perpendicular to the second set of parallel horizontal members 20 to form a plurality of horizontal grid structures supported by the upright members 16. The members 16, 18, 20 are typically made of metal. The bins 10 are stacked between the members 16, 18, 20 of the frame structure 14, such that the frame structure 14 prevents horizontal movement of the stacks 12 of bins 10 and guides vertical movement of the bins 10.

The top layer of the truss structure 14 includes rails 22 arranged in a grid pattern and spanning the top of the stack 12. Referring again to fig. 3 and 4, the rail 22 supports a plurality of robotic load handling devices 30. The first set 22a of parallel rails 22 guide movement of the load handling apparatus 30 in a first direction (X) across the top of the frame structure 14, while the second set 22a of parallel rails 22 arranged perpendicular to the first set 22a guide movement of the load handling apparatus 30 in a second direction (Y) perpendicular to the first direction. In this manner, the rails 22 allow the load handling apparatus 30 to be moved laterally in two dimensions in a horizontal X-Y plane so that the load handling apparatus 30 can be moved to a position above any stack 12.

Norwegian patent No. 317366 further describes one form of load handling apparatus 30, the content of this application being incorporated herein by reference. Fig. 3 (a) and 3 (b) are schematic cross-sectional views of the load handling apparatus 30 of the storage box 10, and fig. 3 (c) is a schematic front perspective view of the load handling apparatus 30 of the lifting box 10. However, there are other forms of load handling equipment that may be used in conjunction with the systems described herein. For example, PCT patent publication No. WO2015/019055 (Ocado), the contents of which are incorporated herein by reference, describes another form of robotic load handling apparatus in which each robotic load handler covers only one grid space of a framework structure, thus allowing for a higher density of load handlers and thus higher throughput for a system of a given size.

Each load handling apparatus 30 comprises a carrier 32, the carriers 32 being arranged to travel in X and Y directions on the rails 22 of the frame structure 14 above the stack 12. A first set of wheels 34, consisting of a pair of wheels 34 on the front of the carrier 32 and a pair of wheels 34 on the back of the carrier 32, is arranged to engage with two adjacent tracks of the first set 22a of tracks 22. Similarly, a second set of wheels 36, consisting of pairs of wheels 36 on each side of the carrier 32, is arranged to engage with two adjacent tracks of the second set 22b of tracks 22. Each set of wheels 34, 36 may be raised and lowered such that either the first set of wheels 34 or the second set of wheels 36 engage the respective set of tracks 22a, 22b at any time.

When the first set of wheels 34 is engaged with the first set of rails 22a and the second set of wheels 36 is lifted off the rails 22, the wheels 34 may be driven by a drive mechanism (not shown) housed in the carrier 32 and move the load handling apparatus 30 in the X-direction. To move the load handling apparatus 30 in the Y-direction, the first set of wheels 34 is lifted off the track 22 and the second set of wheels 36 is lowered into engagement with the second set of tracks 22 a. The drive mechanism may then be used to drive the second set of wheels 36 to effect movement in the Y direction.

The load handling apparatus 30 is equipped with a lifting apparatus. The lifting device 40 comprises a clamping plate 39 suspended from the body of the load handling device 32 by four cables 38. The cable 38 is connected to a winding mechanism (not shown) housed within the carrier 32. The cable 38 may be wrapped in the load handling apparatus 32 or wrapped from outside the load handling apparatus 32 so that the position of the clamping plate 39 relative to the carrier 32 may be adjusted in the Z-direction.

The clamping plate 39 is adapted to engage with the top of the tank 10. For example, the clamping plate 39 may include pins (not shown) that mate with corresponding holes (not shown) in the rim that form the top surface of the tank 10, and sliding clamps (not shown) that may engage the rim to clamp the tank 10. The clamps are driven into engagement with the tank 10 by a suitable drive mechanism housed within the clamping plate 39, wherein the drive mechanism is powered and controlled by signals transmitted either through the cable 38 itself or through a separate control cable (not shown).

To remove the bin 10 from the top of the stack 12, the load handling apparatus 30 is moved in the X and Y directions as required so that the clamping plate 39 is placed over the stack 12. The clamping plate 39 is then lowered vertically in the Z direction into engagement with the bin 10 at the top of the stack 12, as shown in fig. 3 (c). The clamping plate 39 clamps the tank 10 and is then pulled upward with the cable 38 along with the attached tank 10. At the top of its vertical travel, the tank 10 is housed within the carrier body 32 and is placed above the level of the rails 22. In this manner, the load handling apparatus 30 may be moved to different positions in the X-Y plane, transporting the bin 10 along with the bin 10 and transporting the bin 10 to another location. The cable 38 is long enough to allow the load handling apparatus 30 to retrieve and place bins from any level of the stack 12, including the floor level. The weight of the carrier 32 may comprise a portion of a battery that is used to power the drive mechanism for the wheels 34, 36.

As shown in fig. 4, a plurality of identical load handling apparatuses 30 are provided so that each load handling apparatus 30 can operate simultaneously to improve the throughput of the system. The system shown in fig. 4 may include a specific location (referred to as a port) where the tank 10 may be transported into or out of the system. An additional conveyor system (not shown) is associated with each port so that bins 10 transported to the port by load handling apparatus 30 may be transported by the conveyor system to another location, such as to a picking station (not shown). Similarly, the bins 10 may be moved from an external location to a port by a conveyor system, such as to a bin filling station (not shown), and transported by the load handling apparatus 30 to the stack 12 to replenish inventory in the system.

Each load handling apparatus 30 can lift and move one bin 10 at a time. If it is desired to retrieve a bin 10b that is not at the top of the stack 12 ("target bin"), the overlying bin 10a ("non-target bin") must first be moved to allow access to the target bin 10b. This is achieved in an operation hereinafter referred to as "digging".

Referring to fig. 4, during a digging operation, one of the load handling apparatuses 30 sequentially lifts each non-target bin 10a from the stack 12 containing the target bins 10b and places it in an empty position within the other stack 12. The target bin 10b may then be accessed by the load handling apparatus 30 and moved to a port for further transport.

Each load handling device 30 is under the control of a central computer. Each individual bin 10 in the system is tracked so that the appropriate bin 10 can be retrieved, transported, and replaced as needed. For example, during the digging operation, the location of each non-target bin 10a is recorded so that the non-target bin 10a can be tracked.

The system described with reference to fig. 1-4 has many advantages and is suitable for a wide range of storage and retrieval operations. In particular, it allows for very dense storage of products and can provide a very economical way to store a large number of different goods in bins 10 while allowing for reasonably economical access to all bins 10 when picking is required.

Disclosure of Invention

In summary, the present invention introduces a mechanical handling device capable of receiving a delivery container (e.g., a box) at a first location, moving the delivery container to a second location, and then loading it in a loading framework. The first location may be an output of the storage and retrieval system, and this output may include a branch. The mechanical handling device may be configured to advance the shipping container from a first position within the loading frame to a second position within the loading frame.

According to a first aspect of the present disclosure, there is provided a delivery container handling device for an automated storage and retrieval system, the delivery container handling device comprising: a portal frame; a delivery container handler including a first push arm and received on the gantry such that the delivery container handler can be moved on the gantry; the delivery container handling device is configured to, in use: moving a delivery container processor on the gantry to one of a first set of predetermined locations to receive delivery containers from the automated storage and retrieval system; moving the delivery container to one of a second set of predetermined locations relative to the delivery loading frame; and activating the first push arm to move the delivery container into the first position in the delivery loading frame at a predetermined location relative to the delivery loading frame.

The first set of predetermined locations may include output locations from one or more branches from the automated storage and retrieval system. The second set of predetermined locations may include a plurality of locations respectively adjacent to a plurality of locations within the delivery loading frame.

The delivery container handling device may be configured such that the gantry may move the delivery container handler in a first and/or second direction and the push arm of the delivery container handler may move the delivery container in a third direction, wherein the first direction, the second direction, and the third direction are orthogonal. Thus, movement of the delivery container handler on the gantry may be employed to include vertical and/or lateral movement while the push arm moves the delivery container forward into the delivery loading frame.

The delivery container handling device may further comprise one or more optical sensors and one or more processor units, the one or more processors being in communication with the one or more processor units, wherein, in use, data generated by the one or more optical sensors is processed by the one or more processor units to determine the position of the delivery container processor relative to the delivery loading frame. In particular, data generated by the one or more optical sensors may be processed by the one or more processor units to determine the location of one or more features delivering the loading framework.

The delivery container handler may be moved on the gantry to a predetermined location relative to the delivery loading frame, but the loading frame may be slightly distorted or damaged through use. The data obtained from the one or more optical sensors may be processed by the one or more processor units to determine the position of the delivery container relative to the frame (e.g., the shelf on which the delivery container is to be mounted) and then adjust the position of the delivery container accordingly before the first push arm is activated.

The delivery container processor may further comprise a retractable element, wherein the retractable element may be selectively activated in use to hold the delivery container in a predetermined position on the delivery container processor. The delivery container handler may be tilted relative to the delivery container handling device. In particular, the delivery container processor is rotatably coupled to the delivery container handling device, and the delivery container further comprises an actuator, wherein the actuator is activatable in use to tilt the support relative to the device. The delivery container handler may further comprise a second push arm, wherein, in use, after the first push arm has pushed the delivery container into the delivery loading frame, the second push arm may be activated to move the delivery container from a first position within the delivery loading frame to a second position within the delivery loading frame.

The delivery container handler may comprise a detector configured to detect, in use, any object protruding from the top of the delivery container when the delivery container is present in the delivery container handler. The first push arm may include a telescoping region configured to retract when the delivery container is received from the automated storage and retrieval system. The collapsible region of the first push arm may be configured to be extended such that the collapsible region pushes the delivery container when the first push arm is activated. The delivery container handling device may further comprise one or more delivery container loading ledges adapted to receive a plurality of delivery containers.

According to a second aspect of the present disclosure, there is provided a storage system comprising: a first set of parallel tracks or rails extending in the X-direction and a second set of parallel tracks or rails extending in the Y-direction, the second set of parallel tracks or rails being transverse to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces; a plurality of stacks of containers located within the footprint of a single grid space; at least one transport device arranged to selectively move in X and/or Y directions on a track above the stack and arranged to transport containers; a picking station arranged to receive containers transported by the at least one transport device so that the products can be packaged in the delivery containers; one or more branches carrying one or more delivery containers in which the product as described above has been packaged and a delivery container handling device.

Drawings

The detailed description of the invention is described by way of example only with reference to the accompanying drawings, in which like reference numerals designate identical or corresponding parts, and in which:

FIG. 1 is a schematic illustration of a frame structure according to a known system;

FIG. 2 is a schematic diagram showing a top view of a stack of bins disposed within the frame structure of FIG. 1;

fig. 3 (a) and 3 (b) are schematic perspective views of a loading processing apparatus storing a box, and fig. 3 (c) is a schematic front perspective view of a loading processing apparatus lifting a box;

FIG. 4 is a schematic diagram of a system showing a load handling apparatus operating on a mesh frame structure;

FIG. 5 is a schematic diagram of an item processing system according to aspects of the present invention;

FIG. 6 shows a schematic depiction of a box handler suspended from a gantry frame;

figures 7 to 11 show schematic depictions of a case holder from different angles when the case is placed;

fig. 12 shows a schematic depiction of the case holder from the front of the case holder;

FIG. 13 shows a schematic view of a tray of case holders;

fig. 14 shows a schematic depiction of a tray with a case holder of an extension element;

FIG. 15 shows a schematic depiction of a flow chart depicting a process for transferring boxes from a branch to a loading framework;

FIG. 16 shows a schematic depiction of a box that has been aligned with an in-service branch;

FIG. 17 shows a schematic depiction of boxes in a location that have been pushed into a loading frame;

figures 18 to 21 show schematic depictions of further embodiments of a bin processor; and

FIG. 22 shows a schematic depiction of a computer device that may be used to control the bin processor.

Detailed Description

Fig. 5 is a schematic diagram of an article handling system 100 according to an aspect of the present invention. The article handling system includes a gantry frame 200 and a case handler 300 supported by the gantry frame 200. The item processing system further includes one or more branches 500 and one or more loading trusses 600. In use, the bins or shipping containers 400 will be filled with goods at the picking station, such as described above with reference to fig. 1-4. After the boxes are filled at the picking station, the boxes may then be routed to branches so that they can be loaded into carriers and thereby enable the contents of the boxes to be delivered to customers. It should be appreciated that a typical order may include a plurality of boxes and the packaging system will coordinate so that each of the boxes that include the order (e.g., which may include a first set of boxes from a first packaging environment (e.g., refrigerated products) and a second set of boxes from a second packaging environment (e.g., ambient products)) are brought together so that they can be loaded onto the same carrier in a manner that effectively unloads and delivers each order.

Typically, boxes received at one or more branches 500 will then be manually tooling into one or more loading frameworks and provide packaging information so that each order can be loaded in an efficient manner. The loaded loading frame may then be loaded into a carrier or stored for subsequent loading into a carrier.

The article handling system 100 enables boxes 400 to be automatically received from branch 500 and loaded into the box handler 300. The box handler may then be moved over the gantry frame to align itself with the appropriate aperture of one of the loading frames 600 so that the box may be loaded onto the loading frame.

Fig. 6 shows a schematic depiction of a box handler 300 suspended from the gantry frame 200, wherein the box is received within the box handler. The gantry frame 200 includes a base 204, a top 202, and a support member 206. Preferably, the base 204 is rectangular in shape and has the same size and shape as the top 202, with each support member perpendicular to the base and top defining a cube space in which the bin handler may be maneuvered. The gantry frame further includes a support frame 210, the support frame 210 being coupled to the support member 206 such that the support frame can be moved parallel to the Z-axis as shown in fig. 6. The case handler is supported by the support frame such that the case handler can be moved across the width of the frame parallel to the X-axis as shown in fig. 6. From one or both of the shorter sides, the case processors may be accessed for maintenance activities or for additional intervention. A safety interlock may be provided to ensure safe operation of the article handling system, for example to prevent an operator from placing his hand in an area where the loading processor may be moving.

In one embodiment, the loading processor may be configured to load the boxes into a first of two loading frames after the second loading frame has been fully loaded, wherein the two loading frames are shown in fig. 5. The operator can remove the second loading frame (by moving it away from the gantry frame 200 to be loaded into a carrier or stored for subsequent loading) to complete the loading process and then replace it with an empty frame for subsequent loading. While the assembled frame is being replaced, other frames can be assembled with boxes.

The gantry frame allows the case handler to move with two degrees of freedom and acceleration and speed high enough to achieve efficient automatic case loading. Such a gantry frame provides a lightweight and compact free-standing structure in which all necessary electrical and electronic components are embedded and which does not require any special installation or alignment. In the preferred embodiment, the gantry frame includes four linear rail guides 207, one on each support member 206. In addition, the gantry frame may include two linear rail guides 211 disposed on the support frame. The gantry frame requires only 4 leveled mounting points on the ground. The following discussion will assume that the gantry frame is mounted on a substantially horizontal floor, and that the "up" and "down" movements with respect to the box should be understood as movements parallel to the Z axis, and the "left" and "right" movements with respect to the box should be understood as movements parallel to the X axis, as shown in fig. 6. In contrast to gantry frames and case handlers, reference to "front" refers to the side facing the loading frame(s), and reference to "back" refers to the side facing the branch(s).

Fig. 7 to 11 show a schematic depiction of the box holder 300 when the box 400 is placed, fig. 12 shows a schematic depiction of the box holder 300 without a box, and fig. 13 and 14 show a schematic depiction of parts of the box holder. The structure and function of the case holder will be described with reference to fig. 7 to 14. The box holder 300 comprises a frame 302, the frame 302 being adapted to engage with the gantry frame such that the box holder is suspended from the gantry frame and is movable along the support frame 210 parallel to the X-axis as shown in fig. 6. The case handler further includes a tray 330 coupled to the case handler frame 302. The tray is rotatable relative to the case handler frame (see below) and includes first and second rotatable joints 304, 305 and first and second tray actuators 306, 307. The case handler may further include a first camera 310, the first camera 310 being mounted to an upper front portion of the case handler frame. The case handler may further include second and third cameras 312, 314 mounted on respective sides of the case handler frame. The second and third cameras may be closer to the tray than the top of the frame box processor frame. The sub-frame 316 is connected to the tray and is received within the space defined by the case handler frame. The protruding cargo detector 318 is connected to the subframe 316 by a rotatable joint 317. The tray includes two guide rails 360, one on each side of the tray. Each of the guide tracks includes a plurality of rollers 362, the plurality of rollers 362 being positioned along the length of the guide track to assist in the movement of the case. The case handler further includes retractable limiters 335, the retractable limiters 335 being raised to a first position such that they are able to limit further movement of the case along the guide track. If the retractable limiters are moved to the second position they will no longer obstruct the case so that the case can move along the guiding track.

The case handler further includes a push arm 340, and the push arm 340 may be used to push the case into the loading frame. The push arm may include a retractable push arm flap 342. When the push arm is retracted in the first position, it is received substantially parallel to the tray 330 such that the case can move along the guide track and over the push arm flap. When the push arm flap is moved to the second position (see fig. 8), the flap may then engage a face of the case, where the case is received within the case handler. The tray further includes a push rod 350, the push rod 350 being actuatable to move the box from a first position of the loading frame to a second position of the loading frame. The push rod may include an end plate 355, the end plate 355 engaging a surface of the case when the case is pushed from the first position to the second position within the loading frame. The case processor may further include a computer device 2200 (see discussion below with reference to fig. 22), the computer device 2200 being configured to receive data from the cameras and other sensors, process the received data, and then generate instructions to cause the case processor to move over the gantry frame. It will be appreciated that the computer controlling the case processor may be located elsewhere in the article handling system and transmit and receive data between the computer and the case processor via an appropriate cable connection, such as via an ethernet cable or equivalent. As will be appreciated from the description below, the computer may be further configured to communicate with a management system so that the computer can transmit and receive data, such as the central computer described above for controlling the actions of the load handling device. Such data may be used to control the operation of the case processor or other system components that interact with the case processor.

Specifically, the camera(s) included within the case processor and computer device 2200 include a computer vision system. The computer vision system may be configured to detect a component portion of the loading frame into which the case is to be loaded. For example, the computer vision system may detect the member(s) of the loading frame (e.g., the vertical member(s) 610, the horizontal member(s) 615, the outer frame rail 620, or the center frame rail 622) and can determine therefrom the aperture into which the box is to be loaded. The camera may generate a multi-point cloud (multipoint closed) that may then be analyzed by a computer vision system to determine the location where the framing members are loaded.

Fig. 13 shows a schematic view of a tray 330 of the case handler 300 without a case. In one embodiment of the present invention, the guide track 360 may be fixed relative to the tray while the plurality of rollers 362 are passive. In alternative embodiments, the guide track may extend to the rear (rear) of the tray (see discussion below) when the case is being loaded into the case handler. In this alternative embodiment, a plurality of rollers 362 may be powered.

Fig. 14 shows a schematic depiction of the tray when the retractable push arm flap is extended in the second position and the push arm is at a limit of movement. The push arm and the push arm flap occupy this position when the case has been moved from the case handler into the loading frame. Fig. 14 further shows the push rod 350 in an extended position, i.e. the position it occupies when the box has been pushed into the second position of the loading frame. Fig. 14 shows a depiction of an alternative embodiment of the present invention and shows the guide rail in an extended position to the rear of the tray. Fig. 14 shows the retractable restrictor 335, the retractable restrictor 335 being fixed relative to the guide rail 360 and moving toward the rear of the tray when the guide rail is extended. It will be appreciated that the retractable limiters may be fixed relative to the tray so that they do not move with the guide tracks.

Fig. 15 shows a schematic depiction of a flow chart describing a process for transferring boxes from a branch 500 to a loading framework 600. In step S1500, a box handler is placed at a branch having boxes ready to be loaded. At step S1510, the bin is moved from the branch and into the bin handler. In step S1520, the box handler is moved to a predetermined position with respect to the loading frame. In step S1530, the box is transported to a first location within the loading frame. If this first location is the final location for loading the boxes within the framework, the process of transferring boxes ends and the process returns to step S1500. If this first location is not the final location for loading the box within the framework, then the box is moved to the final location (S1540), and the process returns to step S1500. Each of steps S1500-S1540 will be described in more detail with reference to fig. 5-14.

As described above, the customer order will include one or more ordered goods to be stored in one or more boxes. A typical order may include 30-60 items, which requires several boxes to store all of the items. For efficient operation of retrieving and delivering orders, each of the one or more boxes comprising the order is likely to be loaded at a plurality of different picking stations. The boxes will then need to be packed in the loading frame in the proper order so that they can be unloaded from the loading frame in an efficient manner. Each delivery vehicle may be adapted (accept) to one or more loading frameworks and several customer orders will be assigned to a single vehicle so that the customer orders may be delivered efficiently. Each delivery route is planned such that the customer order may be completed, for example, within a predetermined period of time on a predetermined date. Thus, as each delivery route is planned and assigned to a particular delivery vehicle, the central computer of the storage and retrieval system will determine which boxes need to be loaded on each of the delivery vehicles, and each of the plurality of boxes will be transported by the vehicle to a particular location within the loading framework to assist in efficient unloading of the vehicle and efficient delivery of ordered goods.

Fig. 5 shows an arrangement of gantry frames next to two loading frames 600. Each loading frame 600 includes four shelves, where each shelf includes four locations capable of receiving boxes. Each shelf has a front side, i.e., the side closest to the gantry frame, and a rear side (i.e., the side furthest from the gantry frame). Each shelf also has a right side and a left side defined from the front side such that each shelf includes front right, front left, rear right, and rear left locations. The destination of the box within the loading bay may be defined by the identifier of the loading bay, the shelf of the loading bay, and the location within the shelf thereafter. When the order is completed, the storage and retrieval system may determine the number of boxes needed, which are needed to hold all of the goods comprising the order, and the order will be assigned to a particular delivery vehicle. A loading frame destination may be assigned to each of the boxes with ordered goods so that the boxes may be efficiently loaded.

When the boxes have been packaged in the storage and retrieval system, the boxes will be routed from the picking station to branch 500, and from branch 500, the boxes may be selected by box handler 300 and transported to a distribution site in a predetermined loading framework 600. The picking stations may be connected to the branches by one or more conveyor belts (or similar devices). As shown in fig. 5, a single case handler is arranged to receive cases from both branches 500 and to be able to load the cases on both loading ledges 600. It should be appreciated that this arrangement is exemplary only, and that different numbers of branches, bin handlers, and/or loading frameworks may be combined depending on the operational requirements of the storage and retrieval system.

At the branch, the arrival of the bin is detected (e.g., by an optical sensor such as a photoelectric sensor). The box processor will move on the gantry frame to the branch where the box is present and the box can be identified, for example, by an optical sensor such as a camera, reading a mark (e.g., a bar code or two-dimensional code attached to the box). The body of the box may be used to determine the loading frame destination of the box, for example by querying the management system of the automated storage and retrieval system. Alternatively, the management system of the automated storage and retrieval system may instruct the box processor to move to a branch where a box is present and inform the box processor of the box's assigned frame destination.

Based on the identification of the branch that is carrying the box, the box handler will be moved on the gantry frame along the X-axis and/or Z-axis so that the box handler is aligned with the identified branch when the box is to be received from the branch (step S1500). Once the box handler is prevented with respect to the branch, the box will move from the branch into the box handler (step S1510). In one alternative, the branches may be powered such that the branches can be actuated to move the bins along the branches. In this case, the plurality of rollers 362 of the case handler are passive. Once the box processor is aligned with respect to the branch, the box processor may be configured to receive boxes from the branch. The retractable restrainers 335 may be actuated such that the restrainers 335 are in the first position such that they prevent further movement of the case along the plurality of rollers located in the guide track of the tray. The first and second actuators 306, 307 are also actuated such that the tray is raised relative to the frame of the case handler. Such elevation may assist in the movement of boxes received within the trays of the box handler along the passive rollers. It will be appreciated that in order to make the operation of the mechanical processing system incorporating the case handler described herein more efficient, the activation of the retractable limiter and the first and second actuators may be performed while the case handler is being moved into alignment with the branches.

Fig. 16 shows a schematic depiction of the box handler 300 having been aligned with the in-operation branch 500 (the gantry frame 200 is not shown in fig. 16 for clarity). It can be seen that the first and second actuators have been actuated so that the tray of the case handler has been tilted so that the tray is at substantially the same degree of tilt as the branch 500. When the bin processors are aligned and configured, the branches may then be activated such that the active roller 510 of the branches pushes the bin onto the bin processors. The power of the case and the tilting of the case handler tray enable the case to move forward along the passive rollers 362 of the case handler until the case contacts the retractable limiter 335, which may prevent further movement of the case and ensure that the case is in place within the tray of the case handler. The push arm flap 342 may be activated to move to the second position (see fig. 8). In the second position, the push arm flap prevents the case from moving rearward along the tray so that the case is secured within the tray.

When information about the arrival of the box and the box being carried on the branch is sent to the box handler, the inclination angle of the tray may be transferred to the box handler. Alternatively, the bin processor computer may save data relating to the degree of branch tilt as the bin is being moved into alignment with the branch, and retrieve and process this data. It should be appreciated that the case trays may be inclined at the same angle or at a steeper angle than the branches so that the momentum of the case moves it along the case handler.

In an alternative arrangement, the limbs may be passive and an end stop is provided to prevent the box from falling off the ends of the limbs. In this arrangement, the case handler needs to lift the case from the branch so that the case can be loaded onto the case handler. The case handler would include the tray shown in fig. 14, wherein the guide tracks may extend from the rear of the tray. The box handler may be moved so that the box handler is aligned with the branch, and then the box handler may be configured to receive boxes from the branch. The retractable restraints 335 may be activated such that the restraints 335 are in the first position such that they prevent further movement of the case along the plurality of rollers located in the guide track of the tray. The first and second actuators 306, 307 are also actuated such that the tray is raised relative to the frame of the case handler. Also, to make the operation more efficient, activation of the retractable limiter and the first and second actuators may be performed while the case handler is being moved into alignment with the branches.

When the case handler is in place and ready to receive a case, the guide rail 360 may then be extended to the rear of the case handler so that the guide rail 360 is received under the case while the case is still placed on the branch. The case handler may then lift the case over the end stop of the branch, with the guide rail retracted so that the case is moved forward into the case handler. Once the guide track is in the fully retracted position, the case handler may need to activate the powered roller 362 to move the case forward so that the case contacts the retractable limiter 335. Once the case is stored within the case handler, the push arm flap 342 may be activated such that it moves to the second position to secure the case within the tray of the case handler.

Fig. 6-11 show a case 400 secured within a case handler, wherein a retractable restrictor 335 and push arm flap 342 are activated to restrict movement of the case. A potential problem is that the box may already be packaged such that the goods protrude from the top of the box. This is likely to not cause problems when handling or loading boxes into a loading frame if these goods are pliable, such as parts of a plastic bag that houses one or more other goods, than rigid goods such as cardboard boxes. The case handler includes a protruding cargo detector 318, the protruding cargo detector 318 including a roller tube 319 extending across the width of the case. The protruding cargo detector is free to rotate about the joint 317 and is configured such that the protruding cargo detector applies a limited downward force (e.g., a force of about 10N) to the bin. The protruding cargo detector is capable of sensing any vertical displacement of the roller tube 319. As the bin is moved along the pallet of the bin handler, the roller tube protruding from the cargo detector will also roll along the upper surface of the bin. If rigid cargo protrudes from the case, this will cause the roller tube to move upward, which in turn will cause the protruding cargo detector to send a signal to the case processor computer. If the transmitted information indicates that the vertical displacement of the roller tube exceeds a predetermined value, the processing of the box will be stopped. The predetermined value of the limitation of the vertical displacement of the roller tube may be changed. In addition, alarms may be generated to allow for manual intervention. The roller arm is designed to minimize the risk of flexible cargo, such as bags, catching on the protruding cargo detector. If the top of the box has a lid, for example a box containing frozen goods, the action of the roller arm will press the lid against the box.

Once the case is secured within the case handler, the case handler is moved to a predetermined position relative to the loading frame (step S1520). As previously described, the box is uniquely associated with a location within the loading frame and the box handler will be moved on the gantry frame along the X-axis and/or Z-axis such that the box handler is properly aligned with the loading frame. The case processor includes a plurality of sensors, such as cameras or bar code scanners, that are capable of detecting indicia on the case, such as bar codes and two-dimensional codes. The box processor can detect these markers to identify the box and determine the loading frame location into which the box is to be inserted. This identification of boxes may be in addition to, or as an alternative to, any identification occurring at the branch. A plurality of cameras may also be used to position the case handler to ensure that the case handler is properly aligned once it has been moved to a predetermined position relative to the loading frame. Data from the plurality of cameras may be processed by a box processor computer in the machine vision system to locate the box processor. The image and point cloud data may be analyzed using conventional machine vision techniques, such as template matching, edge detection, curve fitting, and the like. Machine vision techniques may also be used for obstacle detection. Although not shown in fig. 7-11, one or more light sources may be provided alongside one or more of the plurality of cameras to provide sufficient illumination for efficient operation of the machine vision system. In a facility where the machine processing system incorporating the present invention is deployed, the range of variation in ambient light levels means that the light source may be monochromatic, with several monochromatic filters being added to one or more of the plurality of cameras.

When the box handler has been moved to a predetermined position and then aligned with an associated aperture of the loading frame, the box handler may then be transferred into the loading frame (step S1540). The push arm 340 may be activated such that the push arm flap 342 acts on the rear of the case, allowing the case to move along the tray of the case handler and into the loading frame.

Fig. 17 shows a schematic depiction of a box 400 that has been pushed into place in the frame 600 by the push arm flap 342 of the box handler. The frame 600 includes a plurality of vertical members 610 and a horizontal frame 615. The frame may include a number of shelves such that each shelf includes two outer frame rails 620 and a center frame rail 622 that is located midway between the two outer frame rails 620. Each of the frame rails includes a substantially horizontal portion 624 that supports a box that is inserted on the pallet. The boxes are received on the loading frame rails. The loading frame rail may be adapted to receive a box. For example, one or more rollers may be incorporated into the loading frame track to assist in the movement of the box as it is loaded into the loading frame. The loading frame rail may include a guide rail that limits movement of the box in a direction perpendicular to the movement of the box when the box is being loaded into the loading frame. The guide rail may comprise a portion of the loading frame rail that is substantially perpendicular to the remainder of the loading frame rail.

The movement of the push arm can be controlled so that the box is moved to the front location of the loading frame, as shown in fig. 17. The camera and machine vision system of the case handler may be used to control the movement of the push arm or to confirm that the case has been properly loaded. If the final location of the box is the front location of the loading framework, as shown in fig. 17, the box loading process ends and the box handler will position itself by branching to receive additional boxes, i.e. the process described above with respect to fig. 15 will return to step S1500.

As can be seen in fig. 17, each shelf of the loading frame may include, for example, a front location and a back location. If the final location of the box is a back side location, the box will be loaded to the front side location of the shelf as described above. Once the case has been moved to the front location by activation of the push arm 340, the push rod 350 will be activated to push the case from the front location to the back location (step S1540). The movement of the push rod may be controlled so that the box is moved to a location on the back of the loading frame. The camera and machine vision system of the case handler may be used to control the movement of the push rod or to confirm that the case has been moved to the correct position. In the alternative, additional sensors may be provided to control the movement of the push rod or to determine the position of the case within the frame. Once the box has been moved to the back location, the box loading process ends and the box handler positions itself via the branch to receive additional boxes (i.e., the process described above with respect to fig. 15 will return to step S1500).

In the alternative, the push rod may be omitted from the case handler. As described above, the push arm performs a first movement such that the push arm moves the first box from the box handler to a front location of the shelf of the loading frame. The second box may then be loaded into the front location such that the action of the push arm moves the second box to the front location of the shelf of the loading frame and the first box to the rear location of the shelf.

Fig. 18-21 show a schematic depiction of a second embodiment of a case handler 1300, the case handler 1300 being operable to receive a case 400 from a branch of an automated storage/retrieval system such that the case may be loaded into a framework, as described above with respect to fig. 5-17. The case handler 1300 includes a frame 1302, the frame 1302 being adapted to engage the gantry frame 200 such that the case handler is suspended from the gantry frame as shown in fig. 6 and is movable along the support frame 210 parallel to the X-axis. Case processor 1300 includes tray 1330. The tray 1330 includes two drive conveyors 1362, one on each long edge of the tray. The case handler 1300 further includes a push arm 1340 that can be used to push the case into the loading frame. Push arm 1340 may include a retractable push arm flap 1342. When the push arm is retracted in the first position, it is received substantially parallel to the tray 1330 so that the case can be moved along the tray and over the push arm flap by activation of the drive conveyor. When the push arm flap is moved to the second position, the flap may engage a back of the case, wherein the case is received within the case handler. The case handler may further include a push rod 1350, and the push rod 1350 may be activated. To move the box from a first position in the loading frame to a second position in the loading frame. The push rod may include an end plate 1355, the end plate 1355 engaging the back of the case when the case is being pushed from the first position to the second position in the loading frame. The pushrod may be mounted to the frame 1302 above and substantially parallel to the plane of the tray.

The case processor 1300 may include one or more cameras or other sensors that can be used to determine the position of the second case processor relative to the branches and/or the frame, as described above, but they are not shown in fig. 18-21. Similarly, although shown in fig. 18-21, the case handler 1300 may include a protruding cargo detector that may be connected to the tray 1330 of the second case handler, and then to the subframe, by a rotatable joint. The box processor may further include a computer (see discussion below with reference to fig. 22) configured to receive data from the cameras and other sensors, process the received data, and then generate instructions to cause the box processor to move over the gantry frame. As will be appreciated from the following description, the computer may be further configured to communicate with a management system, as described above, such that the computer is able to transmit and receive data, such as a central computer used to control the actions of the load handling device. Such data may be used to control the operation of the case processor or other system components that interact with the case processor. In the alternative, data received from cameras and other sensors may be transmitted to a remote computer, which processes the data and generates the necessary signals to control the movement and operation of the case processor. The remote computer may be located elsewhere in the article handling system or as part of an automated storage and retrieval system.

When the case handler 1300 is aligned with one of the branches, the rollers of the branch may be activated to move the case onto the case handler. Once a box is detected on the conveyor 1362, the conveyor is activated to advance the box along the length of the tray 1330. Alternatively, the conveyor belt 1362 may be activated substantially simultaneously when the branch rollers are activated. The use of a conveyor belt means that the case handler 1300 does not require the retractable restrictor 355 described above with reference to fig. 7-14. Fig. 18 shows a view of the case handler from the front, showing the case that has been moved to the front of tray 1330. Fig. 19 and 20 show the box 400 from the front and left, respectively, placed on the front of the tray 1330. Once the box has been moved to the front of the box handler, the box handler may be moved over the gantry frame so that the box handler is aligned with the loading frame location into which the box is to be loaded. Alternatively, once the box is received on the box handler, and before the box is moved to the front of the tray, the gantry may begin moving the box handler, as this may provide more efficient operation.

Figure 21 shows a view of the case handler from the rear and right when the case has been moved to the front of the tray. It can be seen that the retractable push arm flap 1342 has been activated such that the flap is in the second position and engages the rear of the case. When the case handler 1300 is properly aligned with the loading frame (S1520, see fig. 15), the push arm will be activated such that the case is transported from the case handler to the front location of the loading frame (S1530). If the destination of the box is a front location of the loading frame, the box handler will be moved into alignment with the branch to receive additional boxes (S1500). If the case handler is required to be pushed to the back location of the loading frame, the case handler 1300 will move horizontally and vertically so that activation of the push rod 1350 causes the end plate 1355 to move the case from the front location of the loading frame to the back location of the loading frame. Preferably, the end panels may be substantially aligned with the center of the rear of the box, or with specific areas of the rear of the box. Once the box has been moved to the back location of the frame, the push rod will retract and the box handler will be moved into alignment with the branch to receive additional boxes (S1500).

The operation of the case processor is controlled by a control system that includes computer devices and associated communication networks, devices, software, and firmware. The control system may further include an industrial motion controller drivingly connected to the motor to control all of the actuators and receive inputs therefrom (e.g., limit switches, positions, etc.). Additionally, motion controller I/O or other distributed I/O devices may be used to obtain feedback from sensors received on the case handler, gantry frame, branch, or other components of the article handling system. Additionally, a safety controller may be incorporated into the commodity handling system to ensure functional safety.

By way of example, fig. 22 shows a schematic depiction of a computer device 2200, which computer device 2200 may include a central processing unit ("CPU") 2202 connected to a storage unit 2214 and a random access memory 2206. The CPU 2202 may process an operating system 2201, application programs 2203, and data 2223. The operating system 2201, application programs 2203, and data 2223 may be stored in the storage unit 2214 and loaded into the memory 2206 as needed. The computer device 2200 may further include a Graphics Processing Unit (GPU) 2222 operably connected to the CPU 2202 and the memory 2206 to offload intensive image processing computations from the CPU 2202 and run the computations in parallel with the CPU 2202.

An operator 2207 may interact with the computer device 220 using a video display 2208 connected by a video interface 2205, and various input/output devices connected by an I/O interface 2204, such as a keyboard 2215, a mouse 2212, and disk drives or solid state drives 2214. In a known manner, the mouse 2212 may be configured to control movement of a cursor in the video display 2208 and to operate various Graphical User Interface (GUI) controls present in the video display 2208 with mouse buttons. The disk drive or solid state drive 2214 may be configured to accept computer readable media 2216. Computer device 2200 may form part of a network via network interface 2211 and allow computer device 2200 to communicate with other suitably configured data processing systems (not shown). One or more different types of sensors 2235 may be used to receive inputs from various sources. These sensors may include cameras 310, 312, 314 mounted on the case processor as well as other sensors incorporated within the case processor. The computer device may comprise dedicated hardware arranged to control one or more box processors in the above-described item processing system, or the dedicated hardware comprises part of a computing platform for operating the automated storage and retrieval system.

It should be appreciated that control of the case processor may be performed by an appropriately configured industrial computing device, however, the invention may be implemented using almost any kind of computer device, including a desktop computer, a notebook computer, a tablet computer, a wireless handheld device, or a cloud computing platform. The computing device or devices may execute one or more software instances, such as virtual machines and/or containers. The present systems and methods may also be embodied as a computer readable/usable medium including computer program code to enable one or more computer devices to implement each of the various process steps in the methods in accordance with the present invention. Where more than one computer device performs the entire operation, the computer devices may be networked to distribute the various steps of the operation.

It should be understood that the term computer readable medium or computer usable medium includes one or more of any type of physical embodiment of the program code. In particular, the computer-readable/useable medium may comprise program code embodied on one or more portable storage articles of manufacture (e.g., an optical disk, a magnetic disk, a tape, etc.), on data storage portions of one or more computing devices (e.g., memory associated with a computer and/or storage system). In further aspects, the present disclosure provides systems, devices, methods, and computer program products, including non-transitory sets of machine-readable instructions, for implementing such methods and implementing the aforementioned functions.

Many modifications and variations may be made to the above-described embodiments without departing from the scope of the present invention.

The foregoing description has presented several embodiments of the invention for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations may be made without departing from the spirit and scope of the invention.

According to one aspect, the present invention provides a device for handling containers or boxes, the device being configured to: receiving containers from a branch and first location of a semi-automatic or automatic storage and retrieval system; moving the container to a second position corresponding to a predetermined location relative to the loading frame; and moving the container to a first destination location within the loading frame. Alternatively, the container may then be moved to a second destination within the loading frame.

Claims (15)

1. A delivery container handling device for use with an automated storage and retrieval system, the delivery container handling device comprising:

a portal frame;

a delivery container handler including a first push arm and received on the gantry such that the delivery container handler can be moved on the gantry;

The delivery container handling device is configured, in use:

moving the delivery container processor to a first set of predetermined locations on the gantry to receive delivery containers from the automated storage and retrieval system;

moving the delivery container handler to one of a second set of predetermined locations relative to a delivery loading framework; and

the first push arm is activated to move the delivery container to a first position in the delivery loading frame at that predetermined location relative to the delivery loading frame.

2. The delivery container handling device of claim 1, wherein the first set of predetermined locations comprises locations from outputs of one or more branches of an automated storage and retrieval system.

3. The delivery container handling device of claim 1 or claim 2, wherein the second set of predetermined locations comprises a plurality of locations respectively adjacent to a plurality of locations within the delivery loading framework.

4. A delivery container handling apparatus according to any one of claims 1 to 3, wherein the delivery container handling apparatus is configured such that the gantry can move the delivery container handler in a first and/or second direction and the push arm of the delivery container handler can move the delivery container in a third direction, wherein the first direction, the second direction and the third direction are orthogonal.

5. The delivery container handling device of any of claims 1 to 4, wherein the delivery container handling device further comprises one or more optical sensors and one or more processor units, the one or more processors in communication with the one or more processor units, wherein, in use, data generated by the one or more optical sensors is processed by the one or more processor units to determine the position of the delivery container processor relative to the delivery loading frame.

6. The delivery container handling device of claim 5, wherein, in use, data generated by the one or more optical sensors is processed by the one or more processor units to determine the location of one or more features of the delivery loading frame.

7. A delivery container handling apparatus according to any of claims 1 to 6, wherein the delivery container handler further comprises a retractable element which, in use, can be selectively activated to retain a delivery container in a predetermined position on the delivery container handler.

8. A delivery container handling apparatus according to any of claims 1 to 7, wherein the delivery container handler is tiltable relative to the delivery container handling apparatus in use.

9. The delivery container handling device of claim 8, wherein the delivery container handler is rotatably coupled to the delivery container handling device, and further comprising an actuator that is activatable in use to tilt the support relative to the device.

10. A delivery container handling apparatus according to any of claims 1 to 9, wherein the delivery container handler further comprises a second push arm, wherein in use, after the first push arm has pushed the delivery container into the delivery loading frame, the second push arm is activatable to move the delivery container from a first position within the delivery loading frame to a second position within the delivery loading frame.

11. The delivery container handling device of any of claims 1 to 10, wherein the delivery container processor further comprises a detector configured to detect, in use, any object protruding from the top of the delivery container when the delivery container is present in the delivery container processor.

12. The delivery container handling apparatus of any of claims 1 to 11, wherein the first push arm comprises a collapsible region that is configurable to retract when receiving a delivery container from the automated storage and retrieval system in use.

13. The delivery container handling device of claim 12, wherein the telescoping region of the first push arm is configurable to be extended in use such that the telescoping region pushes the delivery container when the push arm is activated.

14. The delivery container handling apparatus of any of claims 1 to 13, wherein the delivery container handling apparatus further comprises one or more delivery loading ledges adapted to receive a plurality of delivery containers.

15. A storage system, the storage system comprising:

a first set of parallel tracks or rails extending in the X-direction and a second set of parallel tracks or rails extending in the Y-direction, the second set of parallel tracks or rails being transverse to the first set in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces;

a plurality of stacks of containers located below the track such that each stack is located within a footprint of a single grid space;

At least one transport device arranged to selectively move in X and/or Y directions on the rail above the stack and arranged to transport containers;

a picking station arranged to receive containers transported by the at least one transport device such that products may be packaged into delivery containers;

one or more branches carrying a plurality of delivery containers in which the product has been packaged into a delivery container handling device according to any one of claims 1 to 14.